Description:PROCESS OF MANUFACTURING ENGINE VALVE COLLETS

Field of the invention

The present disclosure generally relates to combustion engines of an automobile and more particularly, to a process of manufacturing engine valve collets for use in internal combustion engines.

Background of the invention

Valve collets are mainly used in internal combustion engines and have the functions of attaching the valve spring retainers to the valves so that the valve spring always holds the valve in the required position. Internal combustion engines are made of six cylinders, four cylinders, two cylinders or even single cylinder. Generally, per cylinder, there are two or four valves and every valve need a pair of collets. That means for four cylinder four valve car require 32 collets. Volume requirement for collets is very high. Formally valve collets were in various shapes and sizes. A valve collet is made from different chemical elements. The valve collet can be sub divided into 2 groups according to their functions:
a) clamping type, single groove and multi groove where the frictional connections between the valve collets and spring retainers are obtained in any operating situation; and
b) non-clamping type, single groove and multi groove which allow free rotation of valve.

Clamping collets transmit the force through friction connection and a gap between the collet valves is necessary for this to happen. The valve collets have various critical dimensions, such as, taper angle bid height, bid radius, concavity and convexity of the outside surface, surface finish, heat treatment parameters, corner radius and like. These typical parameters directly decide the functional effectiveness which requires to be monitored on continuous basis in the production process. However, the existing processes and machines used in manufacturing collets involve draw mark, shear mark and protrusion issues on a vertical die setup. Further, these processes require more power consumption. Furthermore, these processes involve manual visual inspection that does not catch any profile defect easily. Further the manual inspection has additional drawback of being dependent on the skills of the inspector. The other drawback present processes have is less productivity with Burr projections on the finished product.

Accordingly, there exists a need to provide a process of manufacturing valve collets that overcomes the above-mentioned drawbacks of the prior art.

Objects of the invention

An object of the present disclosure is to reduce the power consumption required in the manufacturing valve collets.

Another object of the present disclosure is to overcome the problems of draw marks, shear marks and protrusion issues associated with the prior art processes.

Yet another object of the present disclosure is to atomize the inspection process thereby enhancing the capabilities to catch any profile defect easily.

Summary of the invention

Accordingly, the present disclosure provides a process of manufacturing valve collets.

In an implementation of the present disclosure a process of manufacturing valve collets is disclosed. The process comprises steps of receiving 108, a straighten coil strand and placing in a cavity of a sizing tool 4.1 defined by two edges. Further cutting 110 the straighten coil strand into specific desired length to obtain a strip using the two edges of the sizing tool 4.1. In accordance with the implementation simultaneously 112 moving a forming tool 4.2, a bottom punch/die 4.3, toward the strip to obtain the valve collet. Further the bottom punch 4.3 is mounted in a horizontal direction and move along the horizontal direction. The method further discloses cutting 114 non-required additional material from the valve collet using a cutter 4.4. is bought into contact with the valve strip to cut non-required additional material from the valve collet.

In another implementation a system for manufacturing valve collets is disclosed. The system comprises a coil stand 1 is configured to hold loops of coil strands. Further a straightener 2 mechanically connected to the coil stand 1. The system further comprises a feeding mechanism 3 positioned downstream to the straightener 1. The feeding mechanism 3 is configured to receive the coil strands. In accordance with the present implementation the system further comprises a collet forming area 4, mechanically coupled with the feeding mechanism 3. The collet forming area 4, further comprises a sizing tool 4.1. The sizing tool 4.1, further comprises a cavity defined by two edges of the sizing tool 4.1. Further a forming tool 4.2, positioned such that the forming tool 4.2, is enclosed within the sizing tool 4.1. Further a bottom punch 4.3 mounted in a horizontal direction and is mechanically connected to the forming tool 4.2.

Brief description of the drawings

The objects and advantages of the present disclosure will become apparent when the disclosure is read in conjunction with the following figures, wherein

Figure 1 illustrates an exemplary embodiment system, in accordance with the present disclosure.

Figure 2, illustrates an exemplary embodiment of a collet forming area, in accordance with the present disclosure.

Figure 3, a method for fabrication of a valve collet in accordance with the exemplary embodiment.

Detailed description of the invention

The foregoing objects of the present disclosure are accomplished and the problems and shortcomings associated with the prior art, techniques and approaches are overcome by the present disclosure as described below in the preferred embodiment.

The present disclosure provides a process of manufacturing valve collets used in internal combustion engines of an automobile. These valve collets perform the function of attaching the valve spring retainers to the valve in order to hold this valve in the required position. The process of the present disclosure overcomes the problems of draw marks, shear marks and protrusion issues associated with the prior art processes. The process of the present disclosure facilitates easy changeover of the setup and provides better tool life. The process of the present disclosure reduces the power consumption from 7.5 HP required in prior art processes to 5.5 HP.

In accordance with the exemplary embodiment, the method for manufacturing the valve collet comprises developing profile strip using rolling mills. The rollers ensure that desired elongation, hardness, tensile strength is achieved during the rolling.

In the next step, the process involves testing the developed profile strip. Specifically, the profile strip undergoes various chemical and mechanical properties tests, subsequently some other dimensional parameters check with the help of a profile projector.

In the next step, the process involves feeding the tested strip through a feeder into shaping tools. In the context of the present disclosure, the shaping tools having a horizontal die arrangement is selected. In the horizontal die arrangement, a movable die exerts pressure and cuts the strip to a pre-determined length. The cut strip falls into a fixed die in desired profiles thereby giving final product i.e. valve collet. From both the arrangements, the collets are ejected through an ejection conveyer and the collets are collected in a tray.

In a final step, the process involves inspecting and packing the collets. The collets go through a visual inspection and packing using an automated process. Collets profile dimensions are automatically visually inspected for correct profile and dimensional accuracy, the acceptable parts are packed automatically towards an outlet of machine while the not acceptable parts fall in the tray.

In accordance with the disclosure for visual inspection the job or the valve collet are observed for dent marks, damages like chipped edges, RM defects, line marks, feeding marks, and dust marks.

In accordance with the present disclosure, the draw mark is resolved with less contact in forming area, a shearing mark is improved with new delayed CAM and a protrusion mark is improved with less contact of forming tools thereby providing tangential relief.

The present disclosure is now illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in bracket in the following description.

Referring to Figures 1 illustrates a system for fabricating valve collets in accordance with the present disclosure is shown.

The valve collets manufactured are used in internal combustion engines of an automobile.

In accordance with the Figure 1, the system may comprise a coil stand 1. The coil stand 1 may be configured to hold loops of coil strands and the material of the coil strands are annealed and tempered. Further the coil stand 1 may be mechanically connected to a straightener 2. The straightener 2 may be positioned adjacent to the coil stand 1, to enable easy transfer of coiled strands from the coil stand 1 to the straightener 2. The coil stand 1 may be configured to rotates in bearing provided at either end of the coil stand 1 while transferring the looped coiled strand to the straightener 2.

The straightener 2 may further comprise a first set of rollers, and a second set of rollers. The first set of rollers and the second set of rollers may be positioned opposite to each other such that they exert pressure on the coil strand. Further in accordance with an exemplary embodiment, the first set of rollers and the second set rollers may have threads or a defined pattern on a surface in contact with the coil.

In accordance with the exemplary embodiment the system may comprise a feeding mechanism 3. The feeding mechanism 3, may further comprise a feeding gripper. The feeding grippers may be configured to receive the straighten coil from the first set of rollers, and the second set of the rollers. The feeding mechanism 3 may be further configured to feed a defined length of straighten coil into a collet forming area 4. Further the defined length of the straighten coil is fabricated into a valve collet. In according to an aspect of the disclosure, fabricating the straighten coil to obtain the collet by impacting a horizontally positioned die on the straighten coil.

The advantage of having a horizontal die is:
- Enables a longer material flow path compared resulting in improved material flow characteristics and more uniform material distribution, leading to better product quality and performance.
- The horizontal dies can potentially provide better heat dissipation compared to vertical dies.

Furter in accordance with the exemplary embodiment, system for fabricating valve collets may further comprise a slug collecting area 7. The slug collecting area 7 is configured to receive discarded material after obtaining the valve collet by fabrication. Further a motor 6 may be configured to provide motion to various cams operating the system.

Further in accordance with the exemplary embodiment a continuous flow of oil may be provided to remove slug and part from bottom punch. Further oil may be pumped under 0.1 MPa pressure and maintained to 15 PSI.

Now referring to Figure 2, illustrates an exemplary embodiment of a collet forming area, in accordance with the present disclosure. The collet forming area 4, may comprise a sizing tool 4.1. The sizing tool 4.1, may be positioned adjacent to the feeding mechanism 3. The straighten coil strand may of a defined length may be received from the feeding mechanism 3, the straighten coil strand may be placed in a cavity defined by two edges on the sizing tool 4.1. The two edges may be at distal end and opposite to each other. The two edges of the sizing tool 4.1, may be configured to cut the straighten coil strand into specific desired length to obtain a strip. To cut the straighten coil strand either the sizing tool 4.1 may be moved so as to come into contact with the straighten coil strand or move the straighten coil strand to be in contact with the sizing tool 4.1.

Further in accordance with the exemplary embodiment, a forming tool 4.2, may be positioned such that the forming tool 4.2, is enclosed within the sizing tool 4.1. The forming tool 4.2, enables moving of the strip in a direction towards a bottom punch/die 4.3, while simultaneously moving the bottom punch 4.3 towards the strip in horizontal direction, thereby having the bottom punch 4.3 mounted in the horizontal direction. Once the bottom punch 4.3, imparts the desired shape into the strip to obtain the valve collet, a cutter 4.4 is bought into contact with the valve strip to cut non-required additional material from the valve collet.

Referring to Figure 3, a method for fabrication of a valve collet in accordance with the exemplary embodiment. In accordance with the exemplary embodiment at step 102, providing looped coil strands by a coil stand 1 to a straightener 2. Further at step 104, receiving at the straightener 2, coil strands and feeding the coil strands into a first set of rollers, and a second set of rollers to obtain a straighten strand. The first set of rollers and the second set of rollers may be positioned opposite to each other such that they exert pressure on the coil.

Further at step 106 grabbing by a feeding mechanism 3, the straighten strand, and further providing the straighten coil strand to a collet forming area 4. The feeding mechanism 3 may be further configured to feed a defined length of straighten coil into a collet forming area 4.

In accordance with the exemplary embodiment, at step 108, receiving, the straighten coil strand and placing in a cavity of a sizing tool 4.1 defined by two edges. At step 110 cutting the straighten coil strand into specific desired length to obtain a strip using the two edges of the sizing tool 4.1. Further at step 112, simultaneously moving a forming tool 4.2, a bottom punch/die 4.3, the strip to obtain the valve collet. The bottom punch 4.3, may be positioned in horizontal direction. Further at step 114, cutting non-required additional material from the valve collet using a cutter 4.4. is bought into contact with the valve strip to cut non-required additional material from the valve collet.

Advantages of the invention

1. The process of the present disclosure overcomes the problems of draw marks, shear marks and protrusion issues associated with the prior art processes.
2. The process of the present disclosure facilitates easy changeover of the setup and provides better tool life.
3. The process of the present disclosure reduces the power consumption from 7.5 HP required in prior art processes to 5.5 HP.
4. The process of the present disclosure atomizes the inspection process thereby enhancing the capabilities to catch any profile defect easily.

The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present disclosure and its practical application, to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the scope of the present disclosure.
We claim:

1. A process of manufacturing valve collets, the process comprising the steps of:
receiving 108, a straighten coil strand and placing in a cavity of a sizing tool 4.1 defined by two edges;
cutting 110 the straighten coil strand into specific desired length to obtain a strip using the two edges of the sizing tool 4.1;
simultaneously 112 moving a forming tool 4.2, a bottom punch/die 4.3, toward the strip to obtain the valve collet, wherein the bottom punch 4.3 is mounted in a horizontal direction and move along the horizontal direction; and
cutting 114 non-required additional material from the valve collet using a cutter 4.4. is bought into contact with the valve strip to cut non-required additional material from the valve collet.
2. The method as claimed in claim 1, further comprises providing 102 looped coil strands by a coil stand 1 to a straightener 2.
3. The method as claimed in claim 1, further comprises receiving 104 at the straightener 2, coil strands and feeding the coil strands into a first set of rollers, and a second set of rollers to obtain the straighten strand.
4. The method as claimed in claim 1, further comprises grabbing 106 by a feeding mechanism 3, the straighten strand.
5. The method as claimed in claim 4, further comprises providing the straighten coil strand to a collet forming area 4.
6. A system for manufacturing valve collets, the system comprises:
a coil stand 1 configured to hold loops of coil strands;
a straightener 2 mechanically connected to the coil stand 1;
a feeding mechanism 3 positioned downstream to the straightener 1, wherein the feeding mechanism 3 is configured to receive the coil strands; and
a collet forming area 4, mechanically coupled with the feeding mechanism 3, wherein the collet forming area 4, further comprises:
a sizing tool 4.1, wherein the sizing tool 4.1, further comprises a cavity defined by two edges of the sizing tool 4.1;
a forming tool 4.2, positioned such that the forming tool 4.2, is enclosed within the sizing tool 4.1; and
a bottom punch 4.3 mounted in a horizontal direction and is mechanically connected to the forming tool 4.2.
7. The system as claimed in claim 6, wherein the coil stand 1 is configured to rotate in a bearing provided at either end of the coil stand 1.
8. The system as claimed in claim 6, wherein the straightener 2 further comprises a first set of rollers, and a second set of rollers.
9. The system as claimed in claim 6, wherein the feeding mechanism 3, further comprise a feeding gripper.
10. The system as claimed in claim 6, further comprises a slug collecting area 7 configured to receive discarded material, and a motor 6 configured to provide motion to various cams.
, Claims:We claim:

1. A process of manufacturing valve collets, the process comprising the steps of:
receiving 108, a straighten coil strand and placing in a cavity of a sizing tool 4.1 defined by two edges;
cutting 110 the straighten coil strand into specific desired length to obtain a strip using the two edges of the sizing tool 4.1;
simultaneously 112 moving a forming tool 4.2, a bottom punch/die 4.3, toward the strip to obtain the valve collet, wherein the bottom punch 4.3 is mounted in a horizontal direction and move along the horizontal direction; and
cutting 114 non-required additional material from the valve collet using a cutter 4.4. is bought into contact with the valve strip to cut non-required additional material from the valve collet.
2. The method as claimed in claim 1, further comprises providing 102 looped coil strands by a coil stand 1 to a straightener 2.
3. The method as claimed in claim 1, further comprises receiving 104 at the straightener 2, coil strands and feeding the coil strands into a first set of rollers, and a second set of rollers to obtain the straighten strand.
4. The method as claimed in claim 1, further comprises grabbing 106 by a feeding mechanism 3, the straighten strand.
5. The method as claimed in claim 4, further comprises providing the straighten coil strand to a collet forming area 4.
6. A system for manufacturing valve collets, the system comprises:
a coil stand 1 configured to hold loops of coil strands;
a straightener 2 mechanically connected to the coil stand 1;
a feeding mechanism 3 positioned downstream to the straightener 1, wherein the feeding mechanism 3 is configured to receive the coil strands; and
a collet forming area 4, mechanically coupled with the feeding mechanism 3, wherein the collet forming area 4, further comprises:
a sizing tool 4.1, wherein the sizing tool 4.1, further comprises a cavity defined by two edges of the sizing tool 4.1;
a forming tool 4.2, positioned such that the forming tool 4.2, is enclosed within the sizing tool 4.1; and
a bottom punch 4.3 mounted in a horizontal direction and is mechanically connected to the forming tool 4.2.
7. The system as claimed in claim 6, wherein the coil stand 1 is configured to rotate in a bearing provided at either end of the coil stand 1.
8. The system as claimed in claim 6, wherein the straightener 2 further comprises a first set of rollers, and a second set of rollers.
9. The system as claimed in claim 6, wherein the feeding mechanism 3, further comprise a feeding gripper.
10. The system as claimed in claim 6, further comprises a slug collecting area 7 configured to receive discarded material, and a motor 6 configured to provide motion to various cams.